Method of manufacturing lined baskets



Sept. 29, 1953 R. H. DE HAVEN METHOD OF MANUFACTURING LINED BASKETSFiled March 7, 1952 R 0 mm. H EE N W m M A E w Rwm E-i -=:r

Patented Sept. 29, 1953 METHOD OF MANUFACTURING LINED BASKETS 7 RobertH. De Haven, Little Rock, Ark., assignor to Little Rock Basket Company,Little Rock,

Ark.

Application March 7, 1952, Serial No. 275,385

6 Claims.

This invention relates to a method for manufacturing baskets, and moreparticularly to means for providing a paper flap at the top of a producebasket or the like so as to protect the contents thereof.

Heretoiore, separate paper caps have been providedrfor use as a topliner in bushel and other produce baskets so as to protect the fruit orvegetables packaged therein from being bruised by the usual wood coverwhich fits on the top of the basket as a closure means. Such separatepaper caps constitute an extra item of expense in manufacture andhandling, and fail to provide a tight seal against loss of the contentsaround the top edge of the basket.

The present invention provides a method of manufacture whereby a paperflap is provided to extend from the basket as a part thereof over thetop of the contents and under the cover so that the top edge of thebasket will be effectively sealed in cooperation with the usual basketcover and bruising of the contents by the cover will be prevented.Installation of such a flap in a basket presents problems in that theprocess must be inexpensive and ideally should be adapted for use withthe existing basket making equipment. The present invention provides amethod of making a basket incorporating such a paper flap so as tosatisfy these requirements.

Accordingly, it is an object of the invention to provide a practicalmethod of attaching a protective fiap to a basket. It is a furtherobject of the invention to provide a basket making process whichincorporates the installation of a protective flap and which may becarried outwith conventional materials on presently existing; basketmaking machines. It is another object of the invention to provide amethod of producing a basket with a protective flap of strong anddurable construction securely anchored in the basket structure. It isstill another object of the invention to provide a method of forming andinstalling a protective flap which is folded so as to facilitatestackingof the baskets prior to use and so as to lie flat over thecontents when the same are packaged therein. Other objects of theinvention will be apparent from the specification and from the drawings,wherein:

Fig. l is an elevation partly insection of a basket manufactured inaccordance with the invention;

Fig. 2 illustrates a length of crepe paper or the like from which thebasket flap of the invention is made;

Fig. 3 shows a step in the method of the invention wherein the paperstrip of Fig. 2 is folded upon itself;

Fig. 4 depicts a pre-formed hoop with the folded paper strip of Fig. 3attached;

Fig. 5 shows the pre-formed hoop of Fig. 4 placed on a conventionalbasket forming machine, in an enlarged scale;

Fig. 6 illustrates another step of the process of the invention whereinthe outside hoops are stapled to the basket; and

Fig. 7 shows a method of use of a completed basket equipped with a paperflap in accordance with the invention.

Referring more particularly to the drawing, Fig. 1 illustrates a typicalbasket it! made with a protective flap E2 in accordance with theinvention. The basket shown is of the straight sided type with threeouter hoops l4, l6, l8 and an inner top strip or hoop 26. This type ofbasket may be made according to the method of the invention on a machineof the kind shown in Figs. 5 and 6, as will be more fully explainedhereinafter. Figs. 5 and 6 show parts of a basket making machine such asis conventional in the basket manufacturing industry, the drawingsshowing the pertinent parts of a machine for making straight sidedbushel baskets such as is disclosed in greater detail in Patent No.1,752,856, granted April 1, 1930, to Albert E. Schmidtke. However, thistype of machine is shown for example only; the invention being equallyapplicable to the manufacture of other forms of baskets such as, forexample, round bottom baskets. More generally, the method of theinvention is adapted for use with machines which staple or .stitchorotherwise fasten the side portions of the formed basket to an innertop hoop or strip member, and has particular utility where the basketside wall portions are formed by the relative movement of an outerbasket wall forming device and an inner basket form upon which the innertop hoop of the basket is first placed.

In carrying out a preferred method of the invention, a piece 22 (Fig. 2)of flexible sheet material such as crepe paper or the like is cut to alength slightly greater than the exterior circumference ofthe top innerhoop 2b of the finished basket. Where the basket is to have a secondhoop i6 spaced downwardly from the top of the basket as is usualpractice, the piece 22 is out to a width-preferably not greater thantwice the distance between the top inner hoop- 20 and the second hoop itplus the width of the top inner hoop. This piece is then foldedunequally as shown in Fig. 3 to form the flap piece I2 with a free edge24 at least as wide as the top inner hoop 20 and a folded portion 26 notWider than the distance between the top inner hoop and the second hoopIS. The folded flap piece I2 is then applied to the customary pre-formedinner hoop 20 as shown in Fig. 4, with the folded portion 26 to theoutside and the free edge 24 overlying the outside surface of the hoopand fastened thereto by any suitable means such as by stapling orstitching as indicated at 30 for example.

Referring to Figs. and 6, the inner hoop 28 with the attached paper flapI2 is then placed hoop end first on a male basket form 32 in positionagainst a locating shoulder 34 thereon, the folded portion 26 being tothe outside so that the hoop can be slipped onto the form expeditiouslywithout danger of the flap being fouled thereby. The remaining steps ofthe basket manufacture are according to common practice as set forth forexample in the above-mentioned patent. A pre-formed basket blank or mat36 is placed between the tapered basket form 32 and a pusher or ram 38having a circular frame 40 carrying an interior freely revolving annulus42, and the ram is brought toward the basket form so that theintermediately placed mat is bent down upon the form by the annulus toprovide basket side wall portions 44 which then overlie the previouslypositioned top inner hoop 20 and its attached flap l2.

A conventional stapling device 46 is then brought into position as shownin Fig. 6 whereupon the basket form 32 is revolved while strips of woodor other suitable material are fed under the staplers and are stapled tothe basket to form the top and second and third outer hoops l4, l6, I8thereof. The staples 48 of the top outer hoop 14 pass through and areclinched inside the inner top hoop 20. In this way the free edge 24 ofthe flap will be tightly bound between the inner top hoop and theoverlying side wall portions of the basket while the folded portion 26will remain free of the staples of both the first and second outer hoopsl4, it because of the manner in which it is folded.

The completed basket H! is then removed from the machine and shipped tothe point of use, the flap 12 remaining in its folded condition wherebythe baskets may be stacked one inside another without danger of injuryto the folded portion 26. When the basket is to be used, the flap l2will be pulled upwardly out of the basket and unfolded as shown in Fig.'7. After the produce 50 has been packaged within the basket the flapwill then be pressed down over the top of the contents in its unfoldedcondition as shown and secured in that position by a top cover.

Thus it will be appreciated that the method of the invention forproviding the protective flap involves the addition of only the crepe paer material 22 over that usually used in the manufacture of a basket,and is adapted to be carried out on conventional basket formingmachines. The attachment of the flap to the pre-formed inner hoop 20provides an effective and simple way to introduce the flap into thebasket structure, while such attachment being to the outside of thepre-formed hoop with the flap folded to the outside in no waycomplicates the placement of the hoop 20 on the basket form 32. Althoughit is preferred to pre-form the inner hoop 20 and then attach the flapI2 thereto, it will be understood that the folded flap material could beat- 4 tached to the hoop material before the latter is cut and formed.Alternatively, the folded flap l2 could be applied to the inner hoop 20after the latter is in place on the form 32 just before the ram isactuated.

The provision of the fold 26 not only permits easy assembly of the hoopon the form but also permits the use of a flap of suflicient width foradequate protection while permitting the stapling of the second outsidehoop It to the basket on the usual machine without the staples thereofcatching the flap. Where desired the flap could be additionally foldedto permit a wider flap and still clear the second hoop l6 during thebasket forming operation.

In accordance with the method of the invention the flap is securelyanchored and clamped between the top inner hoop and the top side wallportions of the basket so as to form a part of the structure thereof.Furthermore, the anchorage of the flap is such that the flap extendsfrom the side wall of the basket at the bottom of the top inner hoop sothat it is clear of the top cover member while providing a complete sealagainst leakage around the top edge of the basket.

While only one process has been illustrated and described hereinabove,it will be appreciated that the principles of the invention may beotherwise applied within the scope of the appended claims.

I claim:

1. The method of making a basket having a preformed top interior hoopand a top exterior hoop and a second hoop around the basket sidewall andspaced below said top hoops, and a top protective flap, which comprisesproviding a piece of flexible sheet material at least as long as the topinterior circumference of the basket and no wider than the sum of thewidth of the top interior hoop and twice the distance between the topinterior hoop and said second hoop, folding the sheet lengthwise toprovide a free edge at least as wide as the top inner hoop and a doubledthickness adjacent thereto, the combined width of the free edge and thedoubled thickness being no greater than the interior basket walldistance from the top of the top interior hoop to the second hoop,providing a preformed interior top hoop for the basket, stapling thefolded sheet around outside said interior top hoop by the free edge withthe fold to the outside and clear of the preformed hoop, forming thewall of the basket so as to overlie the free edge and the fold, formingthe top exterior hoop and second hoop on the exterior wall, and staplingthe parts in place through said top hoops and said second hoop.

2. The method of making a basket having a pre-formed top interior hoopand a top exterior hoop and a second hoop around the basket sidewall andspaced below said top hoops, and a top protective flap, which comprisesproviding a piece of flexible sheet material approximately as long asthe top interior circumference of the basket, folding the sheetlengthwise to provide a free edge at least as wide as the top inner hoopand a folded portion adjacent thereto, the combined width of the freeedge and the folded portion being no greater than the interior basketwall distance from the top of the top interior hoop to the second hoop,providing a pre-formed top interior hoop for the basket, stapling thefolded sheet around outside said top interior hoop by the free edge withthe fold to the outside and clear of the pro-formed hoop, forming thewall of the basket so as to overlie the free edge and the fold, formingthe top exterior hoop and second hoop on the exterior wall, and stapling the parts in place through said top hoops and said second hoop.

3. The method of making a basket having a pre-formed top interior hoopand a positionally corresponding top exterior hoop and a second hooparound the basket sidewall and spaced below said top hoops, and a topprotective flap, which comprises providing a piece of flexible sheetflap material at least as long as the top interior circumference of thebasket and no wider than the sum of the width of the top interior hoopand twice the distance between the top interior hoop and said secondhoop, folding the sheet lengthwise to provide a free edge at least aswide as the top inner hoop and a doubled thickness adjacent thereto, thecombined width of the free edge and the doubled thickness being nogreater than the interior basket wall distance from the top of the topinterior hoop to the second hoop, providing a pre-formed top interiorhoop for the basket, stapling the folded sheet around outside said topinterior hoop by the free edge with the free edge overlying the same andwith the fold to the outside and clear of the preformed hoop, placingthe pre-formed hoop on a basket form, forming the wall of the basketabout the pre-formed hoop and the flap material so as to overlie thefree edge and the fold, forming the top exterior hoop and second hoop onthe exterior of the wall, and stapling the parts in place through saidtop hoops and said second hoop, thereby clamping said free edge in placewhile leaving the remainder of the flap material free.

4. The method of making a basket having a pre-formed top interior hoopand a top exterior hoop and a second hoop around the basket sidewall andspaced below said top hoops, and a top protective flap, which comprisesproviding a piece of flexible sheet material at least as long as the topinterior circumference of the basket and no wider than the sum of thewidth of the top interior hoop and twice the distance between the topinterior hoop and said second hoop, folding the sheet lengthwise toprovide a free edge at least as wide as the top inner hoop and a doubledthickness adjacent thereto, the combined width of the free edge and thedoubled thickness being no greater than the interior basket walldistance from the top of the top interior hoop to the second hoop,providing a formed top interior hoop for the basket with the foldedsheet stapled around outside said top interior hoop by the free edgewith the fold to the outside and clear of said top interior hoop,forming the wall of the basket about the pre-formed top interior hoop soas to overlie the free edge and the fold of the attached folded sheet,forming the top exterior hoop and second hoop on the exterior wall, and

stapling the parts in place through said top hoops and said second hoop.

5. The method of making a basket having a pre-formed top interior hoopand a top exterior hoop and a second hoop around the basket sidewall andspaced below said top hoops, and a top protective flap, which comprisesproviding a piece of flexible sheet material approximately as long asthe top interior circumference of the basket, folding the sheetlengthwise to provide a free edge and a folded portion adjacent thereto,the Width of the folded portion being no greater than the interiorbasket Wall distance from the top interior hoop to the second hoop,providing a formed top interior hoop for the basket with the foldedsheet stapled around outside said top interior hoop by the free edgewith the folded portion clear of said top interior hoop and extending nofurther from said top interior hoop than said interior basket walldistance, forming the wall of the basket about the pro-formed topinterior hoop so as to overlie the free edge and the folded portion ofthe attached folded sheet, forming the top exterior hoop and second hoopon the exterior wall, and stapling the parts in place through said tophoops and said second hoop.

6. The method of making a basket having a pro-formed top interior hoopand a top exterior hoop and a second hoop around the basket sidewall andspaced below said top hoops, and a top protective flap, which comprisesproviding a piece of flexible sheet material approximately as long asthe top interior circumference of the basket, folding the sheetlengthwise to provide a free edge at least as wide as the top inner hoopand a folded portion adjacent thereto, the combined width of the freeedge and the folded portion being no greater than the interior basketwall distance from the top of the top interior hoop to the second hoop,providing a formed top interior hoop for the basket with the foldedsheet stapled around outside said top interior hoop by the free edgewith the folded portion clear of said top interior hoop, forming thewall of the basket about the pre-formed top interior hoop so as tooverlie the free edge and the fold of the attached folded sheet, formingthe top exterior hoop and second hoop on the exterior wall, and staplingthe parts in place through said top hoops and said second hoop.

ROBERT H. DE HAVEN.

References Cited in the flle of this patent UNITED STATES PATENTS NumberName Date 694,845 Dowd Mar. 4, 1902 862,300 Albertelli Aug. 6, 19071,199,825 Schmitz Oct. 3, 1916 1,745,542 Johnson Feb. 4, 1930 2,005,594Ridgway June 18, 1935

